Molded finished part and method of making same cross-references to related applications

Abstract

A molded finished part includes a finish insert ( 172 ) with a finish disposed upon a front insert side and a body portion of the molded part. The insert ( 172 ) has a substantially rigid yet resilient layer of moldable material. The layer has opposing front and back insert sides. The part body portion has a body surface that corresponds to the back insert side. The body portion is also formed of moldable material. Further, the body surface and the back insert side are melded together in a substantially indistinguishable interface.

I claim:  
     
         1  A molded part with a finished surface comprising: 
 a back molding finish insert, the insert having a substantially rigid yet resilient layer of a first moldable material, the layer having opposing first and second insert sides, and a finish disposed upon the first insert side; and  
 a body portion of the molded part, the body portion having at least a first body surface that corresponds to the second insert side, the body portion being formed of a second moldable material, the first and the second moldable materials being mutually compatible whereby the first body surface and the second insert side are melded together in a substantially indistinguishable interface.  
 
     
     
         2  A process of fabricating a molded part with a finished surface comprising the steps of: 
 providing a mold, the mold defining a mold cavity, the mold cavity corresponding to a predetermined part configuration, the mold cavity including at least a first cavity surface, the first cavity surface corresponding to a finished surface of the molded part;  
 providing a finish insert, the finish insert being a substantially rigid and resilient member, the finish insert having opposing insert front and back sides, the insert front side including a finished surface, the finished surface corresponding to the first cavity surface;  
 positioning the finish insert into the mold with the finished surface engaging the first cavity surface;  
 closing the mold with the finish insert positioned in the mold cavity;  
 injecting a moldable material into the mold cavity whereby the moldable material flows against the insert back side, the insert front side thereby being pressed against the first cavity surface;  
 opening the mold; and  
 removing the molded part from the mold.  
 
     
     
         3  A process of  claim 2  wherein the step of providing the finish insert further includes forming the finish insert of a moldable material.  
     
     
         4  A process of fabricating a molded part with a finished surface comprising the steps of: 
 providing a mold, the mold defining a mold cavity, the mold cavity being adapted to form a predetermined molded part, the mold cavity including at least a first cavity surface;  
 providing an insert, the insert being a resilient member, the insert having opposing insert front and back sides, the insert front side including an insert front surface that corresponds to the first cavity surface;  
 positioning the insert into the mold with the insert front surface engaging the first cavity surface;  
 then closing the mold with the finish insert so positioned in the mold cavity;  
 injecting a moldable material into the mold cavity so the moldable material flows against the insert back side and the insert front surface presses against the first cavity surface;  
 opening the mold; and  
 removing the molded part from the mold.  
 
     
     
         5  A process of  claim 2  wherein the step of providing the finish insert further includes forming the finish insert of a moldable material.